Model and monitoring basEd real Time process and trAjectory controL for metal deposition in addItive manufaCturing – METALIC

Current challenges in metal additive manufacturing processes can be mainly traced back to complex multi-physics coupling induced by the thermal loading history of the produced part. Caused defects, based on these phenomena, are mostly insufficient geometrical accuracy and low or unpredictable strength properties, which prevent the broad use of the technology in an industrial scale for manufacturing end products. Due to fluctuating material properties and geometry-dependent process parameters, the need for online closed-loop process control and enhanced process strategies is indispensable to achieve high part qualities. The aim of this project is to setup this real-time closed-loop control for freeform metal additive manufacturing processes. This approach will be achieved by the combination of ultra-fast thermal process modeling and planning, accurate in-situ measurements as feedback signal, and by online real-time optimization of selected process parameters and path strategies.